I have a 2006 GSXR 1000 and even though I have ridden it on the track and it is primarily setup as a race bike with the street clothes on, she is not abused. I do not do excessive wheelies or any stunting. I am also anal about the appearance of my bikes, when I scratch it or damage it, I fix it no matter how small.
When I got the recall notice, I tried very hard to get Suzuki to let me do the work to no avail. I have my business because of the way dealers treat our motorcycles and the kind of work they do.
Well the dealer I got very high recommendations for was 200 miles away. So I took the bike to them to do the work. When I got the back (picked up with my truck) and got home, I went over all the work done. This is what I found:
1. All bolts were tighten down as they were supposed to be and the bike was clean.
2. The windscreen was scratched and two of the screws were broken. The bike sat in my garage for two weeks before I found this though. Even though I did not catch this at the time I picked up my bike, I notified them and they did not even offer to help pay for replacement.
On to the problem, when the recall is done a cover is removed as part of the installation of the frame brace. That part is: lower front cover, part# 94457-41G00.
The part can be seen here: inter-fairings
What I learned is that this change affected the air flow over the radiator and my bike ran hotter that normal and actually boiled over for the first time (I live in a desert). Before the recall, my bike on a 114 degree day would run at about 179 to 182 degrees on the freeway at 85MPH indicated. After the recall, it was running 198 to 202+ degrees. This is not acceptable, especially living in the desert.
So I did a full cooling system flush just to eliminate any problem there and then refill with 50/50 mix of distilled water and Prestone Anti-Freeze, along with the appropriate amount of Water Wetter. Then ran the bike in my shop up to 210 degrees (three time) to ensure there were no leaks and that water was flowing in to the over flow tank and back in to the cooling system correctly. No problems found.
Took my bike out and ran it down the freeway, and still no change in the running temperature. So I re-examined the bikes cooling system and this is what I found. The tops of two inter fairings ( Ref. #'s 1 and 2, part numbers: 94461-41G00 and 94462-41G00. See here inter-fairings) at speed were being force out side of the fins of the radiator and changing air flow characteristics. Like water or electricity, air will take the path of least resistance.
Since the dealer who did the work did not return the cover they took out, I had them return the cover. Took a bit of work, but I got it back.
Well I took the bike back apart, I removed the upper bolts (note, the nuts on the back of the frame brace for the radiator hold bolts are not welded on and must be removed first.) and pulled the radiator forward. Now I proceeded to modify the lower front cover, part# 94457-41G00 to fit back in on top of the radiator as it was originally was because it was the part that held the other two inter fairings in the proper position to create the proper air flow as it was originally designed.
I basically had to cut an oval hole in the cover covering most of the right side of the cover to clear the fan and some wiring. Also the rear mounting eyelets because the frame brace is now using the lugs for the cover you now are modifying.
Once I got the cover fit, I proceeded to put my bike back together watching the fit of all the pieces. Once done, looking at the two inter fairings ( Ref. #'s 1 and 2, part numbers: 94461-41G00 and 94462-41G00.), I noticed that now they followed right at the edge of the radiator fins on both sides as they should be.
Went for a short 40 mile test ride to include city streets and freeway. During the city street portion (10 miles to the freeway), my bike ran at 185 to 195 degrees because of the stop and go traffic. But cooled down pretty quick to 182 to 185 once moving. Next was the freeway. I did about 20 miles on the freeway and my bike ran between 179 and 182 (mostly 182) for the distance. Will do a good ride soon for final test, but all indications are that the over heating problem is now resolved.
I did this so all of my fellow riders are aware of a possible problem after the Suzuki recall on the 2005-06 GSXR 1000's. Even though the bike is still in the operating range as specified by Suzuki, but may not be in the normal range is should be before the recall was done.
Here is my original letters to Suzuki and the dealer who did the work (dealer ship who did the work has been removed, as well as the names of the people) regarding this issue:
Bills
Bikes N Service
74875
Hovley Lane East, Suite C
Palm Desert, CA. 92260
Phone:
760-314-7042 Fax: 760-553-1492
Email:
bill@billsbikesnservice.com
July 26, 2009
American
Suzuki MC/ATV Customer Service
P.O.
BOX 1100
Brea,
CA 92822
Re: Issue with Voluntary Safety Recall Campaign #2A08
Bike: 2006 GSXR 1000 VIN# XXXXXXXXXXXXXXXX
Dear Megan:
Enclosed is a letter to (dealer ship removed) regarding a cooling issue since my recall was done and a part that was left off. Prior to this recall, I had no problems what so ever with the cooling system and now I do.
Also upon inspection of the bike, I noticed that a part of the cooling system was removed and not reinstalled (refer to (dealer ship removed) letter). Based on the diagnostics I have done, this maybe a major contributing factor to this problem.
This issue needs to be resolved ASAP and I will not be going back to this dealer.
Sincerely,
William D. Johnson, Owner
Letter to the dealer:
Bills
Bikes N Service
74875
Hovley Lane East, Suite C
Phone:
760-314-7042 Fax: 760-553-1492
Email:
bill@billsbikesnservice.com
July 26, 2009
(dealer ship removed)
Attn: Owner and (removed)
Re: Frame recall for my 2006 GSXR 1000, R/O #XXXXX
Dear Sir’s,
On inspection of my bike on July 10, 2009, I
did find that the radiator cover part number 94457-41G00
was removed and not re-installed. I called your service department and talked to
(removed)
on or about 7-14-2009 and told him about this. He said that per Suzuki, that
part was to be removed and not reinstalled. I told him at that time, I was not
aware of this and nothing was noted in the service bulletin about leaving this
part off, I told him that I wanted my part returned and he said he would take
care of it.
I
have finally had a chance to ride my motorcycle and have found a problem; my
bike is now running up to 20+ degrees hotter. At slow speeds of up to 50- 55
indicated, my bike is running about 10+ degrees hotter than normal for this time
of year. During a brisk run on fairly clear freeway for about 5 miles, this bike
ran 20+ degrees (temperature gauge was showing 200 degrees + and – 3 degrees)
hotter than normal and for the first time in three years boiled over when I
stopped the bike. The temperature outside was about 110 degrees at the time.
I
cleaned and flushed the cooling system and replaced the anti-freeze/ water with
fresh anti-freeze/water and correct amount of Redline Water Wetter. Then I ran a
full diagnostic of the cooling system and running of the bike up to 210 degrees.
The coolant would flow in to the over flow as the engine would heat up and would
draw back in the engine as it cooled down. I repeated this procedure three times
to verify and the results were the same each time.
I
took my bike out again and it is still running hotter than normal and the
temperature was only 95 degrees when I left and 102 degrees when I got back to
my shop. Based on everything that I have done, by you removing the radiator
cover which all allows the inter cowling to move freely, changes the flow of air
over the radiator and at speed this change is more prevalent as the bike cannot
maintain proper cooling.
As
requested earlier in the month verbally to your service rep. (removed),
I want my cover returned within five business days from the receipt of this
letter. If I do not receive my cover, I will order a new one and you will be
billed at the retail price of $30.00 plus of $2.63 tax for a total of $32.63.
Sincerely,
Bill Johnson, Owner
Cc: American Suzuki